A real-time monitoring and fault diagnosis system for a wind turbine gearbox

Abstract

The present invention discloses a real-time monitoring and fault diagnosis system for a wind turbine gearbox, which includes a plurality of vibration sensors and a rotational speed sensor respectively arranged on the gearbox housing, a torque sensor arranged at the driving end of the gearbox, a lubricating oil chip monitoring module and a lubricating oil quality sensor respectively arranged on the lubricating oil return circuit; it further includes a control box, and the control box includes a core module, a data acquisition module and a wireless communication module; the present invention monitors the number of particles in the lubricating oil in real time, judges the wear condition of each part in the gearbox according to the dielectric constant of the oil and the number of chips in the oil, and at the same time monitors the torque at the output end of the gearbox. When it is monitored that the torque of the gearbox is too large, the torque diagnosis module will send out a warning signal or an alarm signal, avoiding damage to the equipment due to excessive torque. At the same time, by detecting the temperature of the generator bearing and coil, early warning is made in time to avoid damage to the equipment due to high temperature factors of the generator.

Description

Technical Field

[0001] The present invention belongs to the field of fault diagnosis, and specifically relates to a real-time monitoring and fault diagnosis system for a wind turbine gearbox. Background Art

[0002] In the prior art, the common methods for gearbox fault detection mainly rely on manual judgment based on vibrations, noises, and oil temperatures generated during the operation of the gears.

[0003] On the one hand, the pressure cable shielding layer is a composite material composed of carbon black, cross-linking agents, etc., and contains a relatively large number of functional groups. During the actual operation of the cable, the shielding layer not only plays a role in uniforming the electric field but also serves as a bridge between the insulating layer and the conductor. Therefore, it is particularly important to evaluate the aging state of the shielding layer.

[0004] On the other hand, there is a prior patent with the name "Gearbox Fault Signal Acquisition Device Based on Acoustic Sensor Array" and the application number CN201720186371.2. This patent uses an acoustic sensor array, which can effectively reduce noise interference and improve the accuracy of collecting acoustic signals, solving the problem that in the prior art, during the process of collecting acoustic signals, it is inevitable to encounter noise and other interferences, which increases the difficulty of fault detection. However, this patent only judges the faults of the gearbox from the perspective of sound extraction, and there is no early warning function for gearbox faults, and it cannot identify faults with small sounds such as gearbox oil leakage.

[0005] There is a prior patent with the name "Wind Power Generation Gearbox Fault Diagnosis Simulation Test Bench" and the application number CN201620494098.5. This patent provides a test bench that is similar to the working principle of a wind turbine and can more accurately simulate the working state of a wind turbine to accurately determine the fault conditions of the wind turbine, so as to save time and improve efficiency. However, this patent only identifies faults through vibration sensors and is not comprehensive.

[0006] In summary, the prior art has the situation of missed judgment in fault identification and cannot give early warnings for faults. Summary of the Invention

[0007] To solve the above problems, the purpose of the present invention is to provide a real-time monitoring and fault diagnosis system for a gearbox that can accurately identify the faults of a wind turbine gearbox and timely send out warning signals.

[0008] To achieve the above purpose, the technical solution of the present invention is as follows:

[0009] The present invention discloses a comprehensive real-time analysis and early warning monitoring system, which includes a plurality of wind power generation devices and generators respectively arranged on the wind power generation devices. A gearbox is connected to the generator, and a liquid oil circuit is connected to the gearbox. A speed sensor for monitoring the motor speed is arranged on the generator. It is characterized in that a plurality of vibration sensors and speed sensors are respectively arranged on the gearbox housing, a torque sensor is arranged at the driving end of the gearbox, a lubricating oil chip monitoring module and a liquid oil quality sensor are respectively arranged on the liquid oil circuit; it further includes a control box, and the control box includes a core module, a data acquisition module and a wireless communication module; the core module is respectively connected to the data acquisition module and the wireless communication module, and the data acquisition module is respectively connected to a plurality of vibration sensors, torque sensors, lubricating oil chip monitoring modules, speed sensors and liquid oil quality sensors.

[0010] Furthermore, it further includes a plurality of temperature sensors arranged in the generator and an environmental temperature and humidity sensor arranged on the outer surface of the wind power generation device. The data acquisition module is respectively connected to the plurality of temperature sensors and the environmental temperature and humidity sensor. The temperature sensors include a motor winding temperature sensor and a motor bearing temperature sensor.

[0011] Furthermore, the vibration sensors include a radial vibration sensor for monitoring the radial vibration of the gear and an axial vibration sensor for monitoring the axial vibration of the gearbox.

[0012] Furthermore, a touch display screen for providing a human-computer interaction interface is arranged on the control box, and the touch display screen is connected to the core module.

[0013] Furthermore, the liquid oil circuit includes an oil pipeline, an oil circulation pump arranged on the oil pipeline, a filter arranged in the oil pipeline for preventing oil pollution, and an oil tank communicated with the oil pipeline.

[0014] Furthermore, it further includes a host computer, and the host computer is connected to the core module through the wireless communication module.

[0015] Furthermore, a state monitoring module for respectively monitoring and recording the real-time state of the gearbox and the real-time state of the generator and a fault diagnosis module for respectively judging the gearbox fault and the generator fault according to the recognition results of the state monitoring module are arranged in the host computer.

[0016] Furthermore, the state monitoring module includes a temperature monitoring module, a vibration monitoring module, a speed monitoring module, a metal chip monitoring module, a liquid oil quality monitoring module and a torque monitoring module.

[0017] Further, the fault diagnosis module includes a temperature diagnosis module, a vibration diagnosis module, a rotational speed diagnosis module, a metal chip diagnosis module, a liquid oil quality diagnosis module, and a torque diagnosis module.

[0018] Further, it also includes oil pans respectively arranged at the bottoms of the gearbox, the generator, and the oil liquid circuit for collecting the leaked oil of the equipment. The lowest point of the oil pan surface is provided with an oil immersion alarm, and the oil immersion alarm is communicatively connected to the data acquisition module.

[0019] The following beneficial effects are achieved by adopting the above solution:

[0020] The present invention monitors the number of particles in the liquid oil in real time, judges the wear conditions of each part in the gearbox according to the dielectric constant of the oil liquid and the number of chips in the oil liquid. At the same time, it also monitors the torque at the output end of the gearbox. When it is detected that the torque of the gearbox is too large, the torque diagnosis module will send a warning signal or an alarm signal, avoiding equipment damage due to excessive torque. At the same time, by detecting the temperature of the generator bearings and coils, early warnings are given in time to avoid equipment damage of the generator due to high temperature factors.

[0021] The present invention sets warning parameters before giving an alarm, gives an early warning before a fault occurs, and deals with the fault in advance.

[0022] The present invention identifies gear machine faults from multiple angles such as the particles, vibration, and torque of the oil liquid, making the identification of gear machine faults more accurate.

[0023] When any one of the equipment in the oil liquid circuit, the gearbox, and the generator has an oil leakage phenomenon, the oil liquid drips into the oil pan and submerges the oil immersion alarm. The oil immersion alarm sends an alarm signal to the core module through the data acquisition module. The touch display screen reads the data in the CPU of Siemens smart-200, gives an alarm on the display interface, and emits an alarm sound. At the same time, the upper computer obtains the alarm signal through the wireless transmission module. Description of the Drawings

[0024] Figure 1 It is a schematic diagram of the hardware connection structure of a comprehensive real-time analysis and early warning monitoring system provided by Embodiment 1 of the present invention;

[0025] Figure 2 It is a schematic diagram of the connection structure between the upper computer of a comprehensive real-time analysis and early warning monitoring system provided by Embodiment 1 of the present invention and each wind power generation device;

[0026] Figure 3 It is a schematic diagram of the connection structure between the upper computer of a comprehensive real-time analysis and early warning monitoring system provided by Embodiment 2 of the present invention and each wind power generation device;

[0027] Figure 4 It is a schematic diagram of the structure of the upper computer in the present invention. Detailed implementation mode

[0028] The following is a further detailed description through specific implementation modes:

[0029] Embodiment 1

[0030] As shown in the appendix Figures 1 to 4 : A comprehensive real-time analysis and early warning monitoring system includes a plurality of wind power generation devices and generators respectively arranged on the wind power generation devices. A gearbox is connected to the generator, a liquid oil circuit is connected to the gearbox, and a speed sensor for monitoring the motor speed is arranged on the generator. It is characterized in that a plurality of vibration sensors and speed sensors are respectively arranged on the gearbox housing, a torque sensor is arranged at the driving end of the gearbox, and a lubricating oil debris monitoring module and a liquid oil quality sensor are respectively arranged on the liquid oil circuit; it also includes a control box, and the control box includes a core module, a data acquisition module and a wireless communication module; the core module is respectively connected to the data acquisition module and the wireless communication module, and the data acquisition module is respectively connected to a plurality of vibration sensors, torque sensors, lubricating oil debris monitoring modules, speed sensors and liquid oil quality sensors.

[0031] It should be noted that the oil quality sensor is mainly used to measure the dielectric constant of the oil, and indirectly reflects the aging condition of the oil. The more metal particles in the oil due to the increased wear of the gears in the gearbox, the larger the value of its dielectric constant, and the more obvious the polarization phenomenon in the oil, and the larger the value of the dielectric constant. Similarly, the lubricating oil debris monitoring module is also used to monitor the content of metal particles in the gearbox and the content of non-metal particles. This device can monitor the number of particles with different diameters and judge the wear condition of the gearbox according to the changing trends of particles with different diameters in different wear stages of the gearbox.

[0032] More specifically, when installing the lubricating oil debris monitoring module and the liquid oil quality sensor, in order to ensure that the oil monitored by the two devices is as consistent as possible with the oil in the gearbox, the lubricating oil debris monitoring module and the liquid oil quality sensor should be installed as close to the gearbox as possible, and the two devices of the lubricating oil debris monitoring module and the liquid oil quality sensor should also be as close to each other as possible.

[0033] More specifically, in this embodiment, the core module uses the CPU module of Siemens smart-200, and the data acquisition module also uses the Siemens series expansion modules that match the core module, including digital input modules, digital output modules, analog input modules, analog output modules, and expansion communication modules. The expansion communication modules include RS485 expansion modules and RS232 expansion modules. The CPU module of Siemens smart-200 has a built-in RJ45 interface and also supports the modbus tcp protocol; in this embodiment, the vibration sensor, torque sensor, lube debris monitoring module, and liquid oil quality sensor are all communicatively connected to the CPU module of Siemens smart-200 through the RS485 expansion module. It should be noted that. And various temperature sensors and the outdoor temperature sensor are communicatively connected to the CPU module of Siemens smart-200 through the analog input module.

[0034] This system also includes multiple temperature sensors arranged inside the generator and an ambient temperature and humidity sensor arranged on the outer surface of the wind power generation device. The data acquisition module is respectively connected to the multiple temperature sensors and the ambient temperature and humidity sensor. The temperature sensors include a motor winding temperature sensor and a motor bearing temperature sensor.

[0035] Among them, the vibration sensor includes a radial vibration sensor for monitoring the radial vibration of the gear and an axial vibration sensor for monitoring the axial vibration of the gearbox.

[0036] In actual use, the radial vibration sensor and the axial vibration sensor have exactly the same model specifications, and the only difference lies in the installation direction. Among them, the radial vibration sensor is installed along the radial direction parallel to the drive end of the gearbox, and the axial vibration sensor is installed along the axial direction parallel to the drive end of the gearbox;

[0037] A touch display screen for providing a human-machine interaction interface is arranged on the control box, and the touch display screen is connected to the core module. The touch display screen is used to display the real-time operation parameters of the on-site generator and the gearbox, and control equipment such as the on-site generator and the gearbox.

[0038] The liquid oil circuit includes an oil pipeline, an oil circulation pump arranged on the oil pipeline, and a filter arranged in the oil pipeline to prevent oil pollution.

[0039] It also includes a host computer, and the host computer is connected to the core module through a wireless communication module.

[0040] The wireless communication module is one of a 4G / 5G communication module, a GPS communication module, and a lora wireless communication module.

[0041] More specifically, the present invention can be installed in a monitoring station and communicatively connected to multiple wind power generation devices for centrally monitoring gearbox failures and generator failures in multiple wind power generation devices.

[0042] Embodiment 2

[0043] The upper computer can also be installed in a wind power generation device for monitoring gearbox failures and generator failures in one wind power generation device. The upper computers in each wind power generation device of the present invention are all communicatively connected to the upper computers in other wind power generation devices through a wireless transmission module, forming a decentralized network connection structure. Even if a wind power generation device somewhere fails, it will not affect the communication between other wind power generation devices. At the same time, the wind power generation device itself already has the ability to operate independently. Even if the station is disconnected from other stations, the device can independently handle on-site failures.

[0044] Embodiment 3

[0045] This embodiment is a further supplement to Embodiment 1. Specifically, it further includes oil storage pans respectively arranged at the bottoms of the gearbox, the generator, and the oil circuit for collecting equipment oil leakage. The lowest point of the oil storage pan is provided with an oil immersion alarm, and the oil immersion alarm is communicatively connected to the data acquisition module. Among them, the oil immersion alarm is also communicatively connected to the CPU module of Siemens smart-200 through an RS485 expansion module.

[0046] When any one of the equipment in the oil circuit, the gearbox, and the generator has an oil leakage phenomenon, the oil drops into the oil storage pan and submerges the oil immersion alarm. The oil immersion alarm sends an alarm signal to the core module through the data acquisition module. The touch display reads the data in the CPU of Siemens smart-200, issues an alarm on the display interface, and emits an alarm sound. At the same time, the upper computer obtains the alarm signal through the wireless transmission module.

[0047] Embodiment 4

[0048] The upper computer is provided with a status monitoring module respectively used for monitoring and recording the real-time status of the gearbox and the real-time status of the generator, and a fault diagnosis module used for respectively judging gearbox failures and generator failures according to the recognition results of the status monitoring module.

[0049] The status monitoring module includes a temperature monitoring module, a vibration monitoring module, a rotational speed monitoring module, a metal chip monitoring module, an oil quality monitoring module, and a torque monitoring module.

[0050] The fault diagnosis module includes a temperature diagnosis module, a vibration diagnosis module, a rotational speed diagnosis module, a metal chip diagnosis module, an oil quality diagnosis module, and a torque diagnosis module.

[0051] More specifically, the temperature monitoring module in the host computer monitors the real-time data of the environmental temperature and humidity sensor, the motor winding temperature sensor, and the motor bearing temperature sensor, stores it, and generates the temperature and humidity trend curves of each sensor; while the temperature diagnosis module pre-sets the alarm upper and lower limits, warning upper and lower limits, and change upper limits of each temperature sensor or temperature and humidity sensor. The range of the alarm upper and lower limits includes the range of the warning upper and lower limits. When the real-time data of temperature or humidity is not between the warning upper and lower limits but between the alarm upper and lower limits, the temperature diagnosis module issues a warning signal. When the real-time data of temperature or humidity is not between the alarm upper and lower limits, the temperature diagnosis module issues an alarm signal; when the absolute value of the change rate of the real-time data of temperature or humidity per unit time exceeds the change upper limit, it indicates data mutation, sensor abnormality, or equipment abnormality, and an alarm signal is issued.

[0052] Similarly, the vibration monitoring module in the host computer monitors the real-time data of the radial vibration sensor for monitoring the radial vibration of the gear and the axial vibration sensor for monitoring the axial vibration of the gearbox, stores it, and generates the vibration trend curves of each sensor; while the vibration diagnosis module pre-sets the alarm upper and lower limits, warning upper and lower limits, and change upper limits of each vibration sensor. The range of the alarm upper and lower limits includes the range of the warning upper and lower limits. When the real-time data of vibration is not between the warning upper and lower limits but between the alarm upper and lower limits, the vibration diagnosis module issues a warning signal. When the real-time data of vibration is not between the alarm upper and lower limits, the vibration diagnosis module issues an alarm signal; when the absolute value of the change rate of the real-time data of vibration per unit time exceeds the change upper limit, it indicates data mutation, sensor abnormality, or equipment abnormality, and an alarm signal is issued.

[0053] The speed monitoring module is used to monitor the real-time data of the current generator speed; the speed diagnosis module sets the speed alarm upper limit and the speed warning upper limit. The value of the speed alarm upper limit is greater than the speed warning upper limit. When the speed exceeds the speed warning upper limit, the speed diagnosis module issues a speed warning signal. When the speed exceeds the speed alarm upper limit, the speed diagnosis module issues a speed alarm signal.

[0054] Similarly, the torque monitoring module is used to monitor the real-time data of the torque at the driving end of the current gearbox. The torque diagnosis module sets the torque alarm upper limit and the torque warning upper limit. The value of the torque alarm upper limit is greater than the torque warning upper limit. When the torque exceeds the torque warning upper limit, the torque diagnosis module issues a torque warning signal. When the torque exceeds the torque alarm upper limit, the torque diagnosis module issues a torque alarm signal.

[0055] The metal debris monitoring module is used to monitor metal particles in the oil, store the data and generate a particle increment curve; the oil quality monitoring module is used to monitor the dielectric constant of the oil, store the data and generate a dielectric constant change curve. The metal debris diagnosis module and the oil quality diagnosis module cooperate. In the metal debris diagnosis module, the upper limit of the number of particles of each diameter for alarm and the upper limit of the number of particles of each diameter for early warning are set. In this embodiment, the upper limit of the number of particles for alarm and the upper limit of the number of particles for early warning of particles with a diameter of 200 - 300μm are mainly set. When the number of particles with a diameter of 200 - 300μm exceeds the upper limit of the number of particles for early warning but is lower than the upper limit of the number of particles for alarm, the oil quality diagnosis module sets the upper limit of the dielectric constant change, and the metal debris diagnosis module issues an alarm signal. When the number of particles with a diameter of 200 - 300μm exceeds the upper limit of the number of particles for alarm and the dielectric constant of the oil is greater than the upper limit of the dielectric constant change, the metal debris diagnosis module issues an alarm signal.

[0056] The present invention monitors the number of particles in the oil in real time, judges the wear conditions of each part in the gearbox according to the dielectric constant of the oil and the number of debris in the oil. At the same time, the torque at the output end of the gearbox is also monitored. When it is detected that the torque of the gearbox is too large, the torque diagnosis module will issue a warning signal or an alarm signal, avoiding damage to the equipment due to excessive torque. At the same time, by detecting the temperature of the generator bearing and coil, early warnings are given in time to avoid damage to the generator due to high temperature factors.

[0057] The present invention sets early warning parameters before alarm, gives an early warning before a fault occurs, and deals with the fault in advance.

[0058] The present invention identifies gear machine faults from multiple angles such as particles, vibration, and torque of the oil, making the identification of gear machine faults more accurate.

[0059] It should be noted that in this article, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article or device.

[0060] The above are only embodiments of the present invention. Common knowledge such as specific structures and characteristics known in the art is not described in detail herein. Those of ordinary skill in the art know all the common general technical knowledge in the technical field to which the invention pertains before the filing date or the priority date, are able to learn all the prior art in this field, and have the ability to apply conventional experimental means before this date. Those of ordinary skill in the art can, under the inspiration given in this application, complete and implement this solution in combination with their own abilities. Some typical well-known structures or well-known methods should not become an obstacle for those of ordinary skill in the art to implement this application. It should be noted that for those skilled in the art, without departing from the structure of the present invention, several deformations and improvements can be made, which should also be regarded as the protection scope of the present invention, and these will not affect the implementation effect of the present invention and the practicality of the patent. The protection scope required by this application should be based on the content of its claims, and the specific implementation manners and the like recorded in the specification can be used to interpret the content of the claims.

Claims

1. A real-time monitoring and fault diagnosis system for a wind turbine gearbox, comprising a plurality of wind power generating devices and generators respectively arranged on the wind power generating devices, a gearbox is connected to the generator, a liquid oil circuit is connected to the gearbox, and a speed sensor for monitoring the motor speed is arranged on the generator, characterized in that, It also includes a plurality of vibration sensors and speed sensors respectively arranged on the gearbox housing, a torque sensor arranged at the driving end of the gearbox, a lubricating oil debris monitoring module and a hydraulic oil quality sensor respectively arranged on the hydraulic oil circuit; it also includes a control box, and the control box includes a core module, a data acquisition module and a wireless communication module; the core module is respectively connected to the data acquisition module and the wireless communication module, and the data acquisition module is respectively connected to the plurality of vibration sensors, torque sensors, lubricating oil debris monitoring module, speed sensors and hydraulic oil quality sensors; It also includes a plurality of temperature sensors arranged in the generator and an environmental temperature and humidity sensor arranged on the outer surface of the wind power generation device, the data acquisition module is respectively connected to the plurality of temperature sensors and the environmental temperature and humidity sensor, and the temperature sensors include a motor winding temperature sensor and a motor bearing temperature sensor; The vibration sensors include a radial vibration sensor for monitoring the radial vibration of the gear and an axial vibration sensor for monitoring the axial vibration of the gearbox; It also includes a host computer, and the host computer is connected to the core module through the wireless communication module; The host computer is provided with a status monitoring module for respectively monitoring and recording the real-time status of the gearbox and the real-time status of the generator, and a fault diagnosis module for respectively judging the gearbox fault and the generator fault according to the identification results of the status monitoring module; The status monitoring module includes a temperature monitoring module, a vibration monitoring module, a speed monitoring module, a metal debris monitoring module, a hydraulic oil quality monitoring module and a torque monitoring module; The fault diagnosis module includes a temperature diagnosis module, a vibration diagnosis module, a speed diagnosis module, a metal debris diagnosis module, a hydraulic oil quality diagnosis module and a torque diagnosis module.

2. The real-time monitoring and fault diagnosis system for a wind turbine gearbox according to claim 1, characterized in that: A touch display screen for providing a human-computer interaction interface is arranged on the control box, and the touch display screen is connected to the core module.

3. The real-time monitoring and fault diagnosis system for a wind turbine gearbox according to claim 1, wherein: The hydraulic oil circuit includes an oil pipeline, an oil circulation pump arranged on the oil pipeline, a filter arranged in the oil pipeline for preventing oil pollution, and an oil tank communicated with the oil pipeline.

4. A real-time monitoring and fault diagnosis system for a wind turbine gearbox according to claim 1, characterized in that: It also includes oil pans respectively arranged at the bottoms of the gearbox, the generator and the hydraulic oil circuit for collecting the leaked oil of the equipment. An oil immersion alarm is arranged at the lowest point of the oil pan surface, and the oil immersion alarm is communicatively connected to the data acquisition module.

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